Building materials comprising agglomerated particles

ABSTRACT

Roofing granules comprising agglomerated inorganic material, and building materials, such as shingles, that include such roofing granules. By fabricating roofing granules from agglomerating inorganic material it is possible to tailor the particle size distribution so as to provide optimal shingle surface coverage, thus reducing shingle weight and usage of raw materials. Additionally, the use of agglomeration permits the utilization of by-products from conventional granule production processes.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Appln.No. 62/884,342 filed Aug. 8, 2019.

FIELD OF THE INVENTION

The invention relates to building materials (such as shingles) thatinclude roofing granules comprising agglomerated inorganic material. Theinvention also relates to roofing granules comprising agglomeratedinorganic material. By fabricating roofing granules from agglomeratedinorganic material, it is possible to tailor the particle sizedistribution so as to provide improved surface coverage for roofingproducts, thus reducing roofing product weight and usage of rawmaterials. Additionally, the use of agglomeration permits theutilization of by-products from conventional granule productionprocesses.

BACKGROUND OF THE INVENTION

Roofing products are an important category of building material. Roofingproducts are often divided into three broad groups: shingles, rollroofing, and underlayment. Roofing shingles have been used extensivelyin residential housing as roof covering due to their aesthetics, ease ofinstallation, water shedding function, and excellent field performanceover a long period of time.

Traditional roofing shingles are based upon a fiberglass or felt matthat is coated and impregnated with an asphalt-based composition that iscoated with roofing granules. Roofing shingles may be single layer stripshingles, laminated shingles having two or more layers, interlockingshingles and large individual shingles in a variety of weights andcolors. Such laminated asphalt shingles are also often referred to ascomposite shingles, architectural shingles or dimensional shingles.

The shingle fiberglass or felt mat serves as a matrix to support theother components and gives the shingle the required strength towithstand manufacturing, handling, installation and service in theintended environment. An asphalt coating formulated for the particularservice application is often applied to the base material to provide thedesired long-term ability to resist weathering and to provide stabilityunder temperature extremes.

Typically, the roofing granules applied to roofing shingles or rollroofing are size-graded stone particles. Different sizes of roofinggranules may be applied to different areas of the shingle surface (e.g.,back surface, headlap, buttlap, etc.) depending on the requiredproperties of a given area. For example, roofing granules may protectthe shingle asphalt from UV and impact damage, provide aesthetic effectson exposed surfaces and impart fire resistance.

It is beneficial to minimize the weight of roofing granules applied tothe shingle or roll roofing in order to reduce (a) roof loading; (b)shipping costs; (c) raw material utilization; and (d) to facilitateinstallation. It is also advantageous to reduce raw material costs bymaking use of by-products of other processes, such as rock fines.

There is thus a need for roofing granules that provide optimal shingleor roll roofing surface covering and that can be made from wastematerials, such as rock fines.

SUMMARY OF THE INVENTION

In one aspect, the invention relates to a method comprising: obtaining(a) at least one of a rock, a mineral, or a combination thereof and (b)a binder; mixing (a) the at least one of a rock, a mineral, or acombination thereof and (b) the binder to produce agglomeratedparticles; and applying the agglomerated particles to a sheet to form aroofing product.

In another aspect, the invention relates to a method comprising: (1)obtaining (a) at least one of a rock, a mineral, or a combinationthereof and (b) a binder, wherein the at least one of a rock, a mineral,or a combination thereof have a particle size passing US Mesh 40; (2)mixing (a) the at least one of a rock, a mineral, or a combinationthereof and (b) the binder to produce unsintered agglomerated particles;and (3) applying the unsintered agglomerated particles to a sheet toform a roofing product.

In another aspect, the roofing product is a shingle or roll roofing.

In another aspect, the binder is present in in the agglomeratedparticles in an amount of 1 wt % to 10 wt % with respect to a totalweight of the agglomerated particles.

In yet another aspect, the binder is present in in the agglomeratedparticles in an amount of about 2 wt % to 10 wt %.

In another aspect, the binder is present in in the agglomeratedparticles in an amount of about 6 wt % to 10 wt %.

In another aspect, the at least one of a rock, a mineral, or acombination thereof comprises one or more of basalt, metabasalt,andesite, and rhyolite.

In another aspect, the binder is at least one of sodium silicate,gypsum, or a combination thereof.

In another aspect, the at least one of a rock, a mineral, or acombination thereof comprises metabasalt.

In another aspect, the binder comprises sodium silicate.

In another aspect, the agglomerated particles have a coating comprisingsilicate and clay.

In another aspect, the mixing uses a pin mixer.

In another aspect, the method further comprises pelletizing theagglomerated particles.

In another aspect, the method further comprises drying the agglomeratedparticles.

In another aspect, the invention relates to a method comprising: (1)obtaining (a) at least one of a rock, a mineral, or combination thereofand (b) a binder; (2) mixing the at least one of a rock, a mineral, or acombination thereof and the binder to produce agglomerated particles;and (3) applying the agglomerated particles to a sheet to form ashingle, wherein, when wt % is assessed with respect to a total weightof the agglomerated particles, (A) the agglomerated particles have aparticle size distribution comprising (1) at least about 10 wt %retained by US Mesh 50 after passing US Mesh 40, (2) at least about 5 wt% retained by US Mesh 60 after passing US Mesh 50, and (3) at leastabout 5 wt % retained by US Mesh 100 after passing US Mesh 70; or (B)the agglomerated particles have a particle size distribution comprising(1) at least about 40 wt % retained by US Mesh 16 after passing US Mesh12, (2) at least about 30 wt % retained by US Mesh 20 after passing USMesh 16, and (3) at least about 20 wt % retained by US Mesh 30 afterpassing US Mesh 20; or (C) the agglomerated particles have a particlesize distribution comprising (1) at least about 1 wt % retained by USMesh 20 after passing US Mesh 16, (2) at least about 40 wt % retained byUS Mesh 30 after passing US Mesh 20, and (3) at least about 2 wt %retained by US Mesh 40 after passing US Mesh 30.

In another aspect, the agglomerated particles have a particle sizedistribution comprising (1) at least about 20 wt % retained by US Mesh50 after passing US Mesh 40, (2) at least about 10 wt % retained by USMesh 60 after passing US Mesh 50, and (3) at least about 10 wt %retained by US Mesh 100 after passing US Mesh 70.

In another aspect, the agglomerated particles have a particle sizedistribution comprising (1) at least about 30 wt % retained by US Mesh50 after passing US Mesh 40, (2) at least about 20 wt % retained by USMesh 60 after passing US Mesh 50, and (3) at least about 20 wt %retained by US Mesh 100 after passing US Mesh 70.

In another aspect, the agglomerated particles have a particle sizedistribution comprising (1) at least about 40 wt % retained by US Mesh16 after passing US Mesh 12, (2) at least about 30 wt % retained by USMesh 20 after passing US Mesh 16, and (3) at least about 20 wt %retained by US Mesh 30 after passing US Mesh 20.

In another aspect, the agglomerated particles have a particle sizedistribution comprising (1) at least about 2 wt % retained by US Mesh 20after passing US Mesh 16, (2) at least about 50 wt % retained by US Mesh30 after passing US Mesh 20, and (3) at least about 10 wt % retained byUS Mesh 40 after passing US Mesh 30.

In another aspect, the agglomerated particles have a particle sizedistribution comprising (1) at least about 5 wt % retained by US Mesh 20after passing US Mesh 16, (2) at least about 60 wt % retained by US Mesh30 after passing US Mesh 20, and (3) at least about 20 wt % retained byUS Mesh 40 after passing US Mesh 30.

In another aspect, the binder is present in in the agglomeratedparticles in an amount of 1 wt % to 10 wt % with respect to a totalweight of the agglomerated particles.

In another aspect, the binder is present in in the agglomeratedparticles in an amount of about 6 wt % to 10 wt %.

In a still further aspect, the binder is at least one of sodiumsilicate, gypsum, or a combination thereof.

In another aspect, the agglomerated particles have a coating comprisingsilicate and clay.

In another aspect, the mixing uses a pin mixer.

In another aspect, the method further comprises pelletizing theagglomerated particles.

In another aspect, the method further comprises drying the agglomeratedparticles.

In another aspect, the invention relates to a shingle or roll roofingcomprising agglomerated particles comprising (a) at least one of a rock,a mineral, or a combination thereof and (b) a binder, wherein, when wt %is assessed with respect to a total weight of the agglomeratedparticles, (A) the agglomerated particles have a particle sizedistribution comprising (1) at least about 10 wt % retained by US Mesh50 after passing US Mesh 40, (2) at least about 5 wt % retained by USMesh 60 after passing US Mesh 50, and (3) at least about 5 wt % retainedby US Mesh 100 after passing US Mesh 70; or (B) the agglomeratedparticles have a particle size distribution comprising (1) at leastabout 40 wt % retained by US Mesh 16 after passing US Mesh 12, (2) atleast about 30 wt % retained by US Mesh 20 after passing US Mesh 16, and(3) at least about 20 wt % retained by US Mesh 30 after passing US Mesh20; or (C) the agglomerated particles have a particle size distributioncomprising (1) at least about 1 wt % retained by US Mesh 20 afterpassing US Mesh 16, (2) at least about 40 wt % retained by US Mesh 30after passing US Mesh 20, and (3) at least about 2 wt % retained by USMesh 40 after passing US Mesh 30.

Among those benefits and improvements that have been disclosed, otherobjects and advantages of this invention will become apparent from thefollowing description. Detailed embodiments of the invention aredisclosed herein; however, it is to be understood that the disclosedembodiments are merely illustrative of the invention that may beembodied in various forms. In addition, each of the examples given inconnection with the various embodiments of the invention which areintended to be illustrative, and not restrictive.

Throughout the specification and claims, the following terms take themeanings explicitly associated herein, unless the context clearlydictates otherwise. The phrases “in one embodiment” and “in someembodiments” as used herein do not necessarily refer to the sameembodiment(s), though they may. Furthermore, the phrases “in anotherembodiment” and “in some other embodiments” as used herein do notnecessarily refer to a different embodiment, although they may. Thus, asdescribed below, various embodiments of the invention may be readilycombined, without departing from the scope or spirit of the invention.

DETAILED DESCRIPTION

One embodiment pertains to a roofing shingle that includes roofinggranules comprised of agglomerated particles. Agglomerated particles maybe applied to the back surface, buttlap and/or headlap of the shingle.In an embodiment, the agglomerated particles applied to the backsurface, buttlap and/or headlap of the shingle have different particlesize distributions. The choice of particle size distribution selectedfor a shingle surface may be influenced by the balance of surfacecoverage, shingle weight, degree of flatness and impact resistancerequired. The shingle may be a single-layer shingle or a laminatedshingle.

Examples of a sheet that may be used to make the shingle are as follows.In particular, in an embodiment, the shingle may be formed from afiberglass mat with an asphalt coating on both sides of the mat. In anembodiment, the shingle may be formed from organic felt or other typesof base material, including synthetic mats or synthetic glass/hybridmats having an appropriate coating. Non-limiting examples of coatingsinclude asphalt and modified bituminous coatings based on atacticpolypropylene (APP), styrene-butadiane-styrene (SBS),styrene-ethylene-butadiene-styrene (SEBS), amorphous polyalpha olefin(APAO), thermoplastic polyolefin (TPO), synthetic rubber or otherasphaltic modifiers.

In an embodiment, two or more shingles are installed on a roof deck in aroofing system such that the shingles are in a row from left to rightand the lateral edges of the shingles in the row are contiguous witheach other so as to abut each other, i.e., their lateral edges areadjacent to one another. Each row represents a course and the shinglesare applied in overlapping courses on the roof deck, wherein the buttlapportion of a subsequent course is placed on the headlap portion of aprevious course. In an embodiment, the headlap portion of the shingle isat least as wide as the buttlap portion of the shingle so that when theshingles are installed on a roof deck in overlapping courses, the entirebuttlap portion of a subsequent course has headlap beneath it. In anembodiment, an edge of the shingle has a plurality of dragon teeth withopenings therebetween. In an embodiment of the laminated shingle, abacker strip is provided under the dragon teeth, with portions of thebacker strip exposed through the openings between the dragon teeth. Inan embodiment of the single layer shingle, when the shingle is installedon a roof deck, the dragon teeth of a second layer of shingles is placedon the headlap of a previously installed layer of shingles, such thatportions of the headlap region are exposed through the openings betweenthe dragon teeth.

One embodiment pertains to a roofing system comprising one or moreshingles that comprise the agglomerated particles.

A. AGGLOMERATED PARTICLES—COMPOSITION

In an embodiment, the agglomerated particles comprise binder andinorganic material. In an embodiment the inorganic material comprisesrock and/or mineral fragments (i.e., fragments of (a) rock and/or (b)mineral). In an embodiment, the rock and/or mineral fragments comprisefines and/or larger particle sizes.

In one embodiment, the rock and/or mineral fragments are of such aparticle size as to pass US Mesh 40. In other embodiments, the rockand/or mineral fragments are of such a particle size as to pass US Mesh50, or US Mesh 60, or US Mesh 70, or US Mesh 100, or US Mesh 120, or USMesh 140, or US Mesh 200, or US Mesh 230, or US Mesh 270, or US Mesh325. Ranges based on any of the foregoing are also contemplated, e.g.,the rock and/or mineral fragments may have particle sizes passing USMesh 40 but retained by US Mesh 270.

Non-limiting examples of binders include sodium silicate, gypsum orother cementitious binders. Non-limiting examples of rock and/or mineralmaterials include igneous rocks such as basalt, andesite, and rhyolite,amphibolite produced from the metamorphism of the basalt parent such asmetabasalt, or combinations thereof—e.g., basalt and metabasalt; basaltand andesite.

In an embodiment, the binder content of the agglomerated particles is atleast about 1 wt %, at least about 2 wt %, at least about 3 wt %, atleast about 5 wt %, or at least about 10 wt %.

In an embodiment, the binder content of the agglomerated particles isfrom about 1 wt % to about 10 wt %. In an embodiment, the binder contentof the agglomerated particles is from about 1 wt % to about 8 wt %. Inan embodiment, the binder content of the agglomerated particles is fromabout 1 wt % to about 6 wt %. In an embodiment, the binder content ofthe agglomerated particles is from about 1 wt % to about 3 wt %. In anembodiment, the binder content of the agglomerated particles is fromabout 1 wt % to about 2 wt %.

In an embodiment, the binder content of the agglomerated particles isfrom about 2 wt % to about 10 wt %. In an embodiment, the binder contentof the agglomerated particles is from about 4 wt % to about 10 wt %. Inan embodiment, the binder content of the agglomerated particles is fromabout 6 wt % to about 10 wt %. In an embodiment, the binder content ofthe agglomerated particles is from about 8 wt % to about 10 wt %.

In an embodiment, the binder content of the agglomerated particles isfrom about 2 wt % to about 8 wt %. In an embodiment, the binder contentof the agglomerated particles is from about 3 wt % to about 6 wt %. Inan embodiment, the binder content of the agglomerated particles is fromabout 2 wt % to about 3 wt %.

In an embodiment, the binder content of the agglomerated particles isabout 3.5 wt %. In an embodiment, the binder content of the agglomeratedparticles is about 3 wt %. In an embodiment, the binder content of theagglomerated particles is about 2.5 wt %. In an embodiment, the bindercontent of the agglomerated particles is about 1 wt %.

In embodiments, the agglomerated particles comprise the binder contentof any of the embodiments detailed herein with the rock and/or mineralfragments forming the remainder.

In an embodiment the agglomerated particles are coated. In anembodiment, the coating is semi-ceramic. In an embodiment, thesemi-ceramic coating comprises silicate and clay. In an embodiment, thecoating provides color to the agglomerated particles. In an embodiment,coated agglomerated particles are applied to the buttlap of the shingle.

In one embodiment, the agglomerated particles consist essentially of, orconsist of, (a) the rock and/or mineral fragments and (b) the binder, or(a) the rock and/or mineral fragments, (b) the binder, and (c) thecoating.

B. AGGLOMERATED PARTICLES—PARTICLE SIZE DISTRIBUTION

In an embodiment, the agglomerated particles have a particle sizedistribution. In an embodiment, the particle size distribution ismonomodal, bimodal or multimodal. That is, the agglomerated particlesmay have one, two or multiple modal sizes.

In an embodiment, the particle size distribution of the agglomeratedparticles applied to the back surface of the shingle comprises at leastabout 10 wt % particles of US Mesh 50, at least about 20 wt % particlesof US Mesh 50, at least about 30 wt % particles of US Mesh 50, or atleast about 40 wt % particles of US Mesh 50. In an embodiment, theparticle size distribution of the agglomerated particles applied to theback surface of the shingle comprises at least about 5 wt % particles ofUS Mesh 60, at least about 10 wt % particles of US Mesh 60, at leastabout 20 wt % particles of US Mesh 60, or at least about 30 wt %particles of US Mesh 60. In an embodiment, the particle sizedistribution of the agglomerated particles applied to the back surfaceof the shingle comprises at least about 5 wt % particles of US Mesh 100,at least about 10 wt % particles of US Mesh 100, at least about 20 wt %particles of US Mesh 100, or at least about 30 wt % particles of US Mesh100.

In an embodiment, the particle size distribution of the agglomeratedparticles applied to the headlap of the shingle comprises at least about20 wt % particles of US Mesh 16, at least about 30 wt % particles of USMesh 16, at least about 40 wt % particles of US Mesh 16, or at leastabout 50 wt % particles of US Mesh 16. In an embodiment, the particlesize distribution of the agglomerated particles applied to the headlapof the shingle comprises at least about 10 wt % particles of US Mesh 20,at least about 20 wt % particles of US Mesh 20, at least about 30 wt %particles of US Mesh 20, or at least about 40 wt % particles of US Mesh20. In an embodiment, the particle size distribution of the agglomeratedparticles applied to the headlap of the shingle comprises at least about5 wt % particles of US Mesh 30, at least about 10 wt % particles of USMesh 30, at least about 20 wt % particles of US Mesh 30, or at leastabout 30 wt % particles of US Mesh 30.

In another embodiment, the particle size distribution of theagglomerated particles applied to the headlap of the shingle comprisesat least about 1 wt % particles of US Mesh 20, at least about 2 wt %particles of US Mesh 20, at least about 5 wt % particles of US Mesh 20,at least about 10 wt % particles of US Mesh 20, at least about 20 wt %particles of US Mesh 20, or at least at least about 30 wt % particles ofUS Mesh 20. In an embodiment, the particle size distribution of theagglomerated particles applied to the headlap of the shingle comprisesat least about 40 wt % particles of US Mesh 30, at least about 50 wt %particles of US Mesh 30, at least about 60 wt % particles of US Mesh 30,at least about 70 wt % particles of US Mesh 30, or at least about 80 wt% particles of US Mesh 30. In an embodiment, the particle sizedistribution of the agglomerated particles applied to the headlap of theshingle comprises at least about 2 wt % particles of US Mesh 40, atleast about 4 wt % particles of US Mesh 40, at least about 10 wt %particles of US Mesh 40, at least about 20 wt % particles of US Mesh 40,at least about 30 wt % particles of US Mesh 40, or at least about 40 wt% particles of US Mesh 40.

C. METHOD OF MAKING THE AGGLOMERATED PARTICLES

One embodiment of this invention pertains to a method of makingagglomerated particles that are applied to the shingles. In anembodiment, rock and/or mineral fragments are combined with a liquid ordry binder in a pin mixer. In the pin mixer, pins or rods attached to ahorizontal spinning shaft mix the components and produce agglomeratedparticles by the action of centrifugal force. In an embodiment, theagglomerated particles produced by the pin mixer are substantiallyspherical. In an embodiment, the agglomerated particles produced by thepin mixer may be dried and used directly. Agglomerated particles made bythe pin mixer may be applied to the back surface or headlap of ashingle.

In another embodiment, the agglomerated particles produced by the pinmixer are combined with further liquid binder in a disc or panpelletizer. The agglomerated particle size is increased by the actionsof tumble growth and centrifugal force. The agglomerated particle sizemay be controlled by varying the disc angle and speed of rotation, andby modulating the properties of the input particles and liquid binder.Once the desired agglomerated particle size is achieved the agglomeratedparticles may be dried. The disc or pan pelletizer increases theagglomerated particle size and produces agglomerated particles that maybe applied to the buttlap of a shingle. In an embodiment, theagglomerated particles are dried after leaving the pin mixer, or disc orpan pelletizer. In an embodiment, the agglomerated particles are driedin a fluid bed drying system. In the fluid bed drying system hot airflows through a perforated plate that both dries the agglomeratedparticles and moves the agglomerated particles through the apparatus. Inan embodiment, the fluid bed drying system comprises multiple heatingzones and a final cooling zone.

D. METHOD OF APPLYING THE AGGLOMERATED PARTICLES TO A ROOFING SHINGLE

In some embodiments, the invention relates to the method of applying theagglomerated particles to a shingle. In some embodiments, the methodincludes application of the agglomerated particles to at least one ofthe back surface, the buttlap or the headlap of the shingle.Manufacturing the shingle includes applying agglomerated particles toasphalt coated sheeting. The asphalt sheet is then pressed in a pressroll unit, such that the agglomerated particles embed in the asphaltcoating. The asphalt sheet is then cut to the desired shape on a machineline. In embodiments, the invention includes the method of making theagglomerated particles and applying the agglomerated particles to ashingle as detailed herein.

In one embodiment, the agglomerated particles are not sintered beforebeing used. In other words, the agglomerated particles are, withoutbeing sintered, used to make a roofing material such as a shingle orroll roofing. As used herein “sintering” is the process of compactingand forming a solid mass of material by heat or pressure without meltingit to the point of liquefaction.

E. EXAMPLES

Specific embodiments of the invention will now be demonstrated byreference to the following examples. It should be understood that theseexamples are disclosed by way of illustrating the invention and shouldnot be taken in any way to limit the scope of the invention.

Examples Example 1

An exemplary particle size distribution of the agglomerated particlesapplied to the back surface of a shingle is given in Table 1.

TABLE 1 US Mesh Tyler Mesh Wt % Retained  30  28  0-0  40  35  0-5  50 48 20-32  60  60 10-20  70  65  6-15 100 100 15-25 140 150  7-17 200200  4-10 Pan Pan  2-11

Further exemplary particle size distributions of the agglomeratedparticles applied to the back surface of a shingle are given in Table 2.

TABLE 2 US Mesh Tyler Mesh Wt % Retained Range  30  28  0.0-0.0  40  35 3.1-4.8  50  48 19.9-21.6  60  60 13.3-13.8  70  65  9.5-10.8 100 10019.5-21.6 140 150 13.2-14.4 200 200  8.8-9.0 Pan Pan  7.3-9.3

An exemplary particle size distribution of the agglomerated particlesapplied to the headlap of a shingle is given in Table 3.

TABLE 3 US Mesh Tyler Mesh Wt % Retained  8  8  0-0 12 10  4-10 16 1430-45 20 20 25-35 30 28 14-24 40 35  2-9 Pan Pan  0-2

A further exemplary particle size distribution of the agglomeratedparticles applied to the headlap of a shingle is given in Table 4.

TABLE 4 US Mesh Tyler Mesh Wt % Retained 12 10  0-0 16 14  0-6 20 20 2-26 30 28 48-76 40 35  4-32 Pan Pan  0-6

The choice of particle size distribution selected for a shingle may beinfluenced by the balance of surface coverage, shingle weight, degree offlatness and impact resistance required.

By way of reference, below is a table, Table 5, showing thecorrespondence between US Mesh, Tyler Mesh, and the sieve opening sizein inches and micrometers:

TABLE 5 ISO Standard Opening Sieve Size inches (in) Standard Mesh mm orμm approximate US Tyler as indicated equivalents mm Mesh Mesh 5.60 mm0.2230 5.600  3.5  3.5 4.75 mm 0.1870 4.750  4  4 4.00 mm 0.1570 4.000 5  5 3.35 mm 0.1320 3.350  6  6 2.80 mm 0.1100 2.800  7  7 2.36 mm0.0937 2.360  8  8 2.00 mm 0.0787 2.000  10  9 1.70 mm 0.0661 1.700  12 10 1.40 mm 0.0555 1.400  14  12 1.18 mm 0.0469 1.180  16  14 1.00 mm0.0394 1.000  18  16 850 μm 0.0331 0.850  20  20 710 μm 0.0278 0.710  25 24 600 μm 0.0234 0.600  30  28 500 μm 0.0197 0.500  35  32 425 μm0.0165 0.425  40  35 355 μm 0.0139 0.355  45  42 300 μm 0.0117 0.300  50 48 250 μm 0.0098 0.250  60  60 212 μm 0.0083 0.212  70  65 180 μm0.0070 0.180  80  80 150 μm 0.0059 0.150 100 100 125 μm 0.0049 0.125 120115 106 μm 0.0041 0.106 140 150 90 μm 0.0035 0.090 170 170 75 μm 0.00290.075 200 200 63 μm 0.0025 0.063 230 250 53 μm 0.0021 0.053 270 270 45μm 0.0017 0.045 325 325 38 μm 0.0015 0.038 400 400 32 μm 0.0012 0.032450 25 μm 0.0010 0.025 500 20 μm 0.0008 0.020 635

As discussed above, one example of rock and/or mineral is basalt;however, metabasalt (which is an amphibolite produced from themetamorphism of the basalt parent) may be used in addition to or insteadof basalt. In other words, where the embodiments use the term basalt,they should be read as describing the use of basalt, metabasalt, or acombination of basalt and metabasalt.

CONCLUSION

While the present teachings have been described in conjunction withvarious embodiments and examples, it is not intended that the presentteachings be limited to such embodiments or examples. On the contrary,the present teachings encompass various alternatives, modifications, andequivalents, as will be appreciated by those of skill in the art.

While various embodiments have been described and illustrated herein,those of ordinary skill in the art will readily envision a variety ofother means and/or structures for performing the function and/orobtaining the results and/or one or more of the advantages describedherein, and each of such variations and/or modifications is deemed to bewithin the scope of the embodiments described herein. More generally,those skilled in the art will readily appreciate that all parameters,dimensions, materials, and configurations described herein are meant tobe exemplary and that the actual parameters, dimensions, materials,and/or configurations will depend upon the specific application orapplications for which the inventive teachings is/are used. Thoseskilled in the art will recognize many equivalents to the specificembodiments described herein. It is, therefore, to be understood thatthe foregoing embodiments are presented by way of example only and that,within the scope of the appended claims and equivalents thereto,embodiments may be practiced otherwise than as specifically describedand claimed. Embodiments of the present disclosure are directed to eachindividual feature, system, article, material, kit, and/or methoddescribed herein. In addition, any combination of two or more suchfeatures, systems, articles, materials, kits, and/or methods, if suchfeatures, systems, articles, materials, kits, and/or methods are notmutually inconsistent, is included within the scope of the presentdisclosure.

All definitions, as defined and used herein, should be understood tocontrol over dictionary definitions, definitions in documentsincorporated by reference, and/or ordinary meanings of the definedterms.

The indefinite articles “a” and “an,” as used herein in thespecification and in the claims, unless clearly indicated to thecontrary, should be understood to mean “at least one.” Put another way,throughout the specification, the meaning of “a,” “an,” and “the”include plural references. Any ranges cited herein are inclusive.

The meaning of “in” includes “in” and “on.”

The terms “substantially”, “approximately,” and “about” used throughoutthis Specification and the claims generally mean plus or minus 10% ofthe value stated, e.g., about 100 would include 90 to 110. Thus, as usedherein, the term “about X” means X plus or minus 10%. For example,“about 10 wt %” means 9 wt % to 11 wt %.

The phrase “and/or,” as used herein in the specification and in theclaims, should be understood to mean “either or both” of the elements soconjoined, i.e., elements that are conjunctively present in some casesand disjunctively present in other cases. Multiple elements listed with“and/or” should be construed in the same fashion, i.e., “one or more” ofthe elements so conjoined. Other elements may optionally be presentother than the elements specifically identified by the “and/or” clause,whether related or unrelated to those elements specifically identified.Thus, as a non-limiting example, a reference to “A and/or B”, when usedin conjunction with open-ended language such as “comprising” may refer,in one embodiment, to A only (optionally including elements other thanB); in another embodiment, to B only (optionally including elementsother than A); in yet another embodiment, to both A and B (optionallyincluding other elements); etc.

As used herein in the specification and in the claims, “or” should beunderstood to have the same meaning as “and/or” as defined above. Putanother way as used herein, the term “or” is an inclusive “or” operator,and is equivalent to the term “and/or,” unless the context clearlydictates otherwise. For example, when separating items in a list, “or”or “and/or” shall be interpreted as being inclusive, i.e., the inclusionof at least one, but also including more than one, of a number or listof elements, and, optionally, additional unlisted items. Only termsclearly indicated to the contrary, such as “only one of” or “exactly oneof,” or, when used in the claims, “consisting of,” will refer to theinclusion of exactly one element of a number or list of elements. Ingeneral, the term “or” as used herein shall only be interpreted asindicating exclusive alternatives (i.e. “one or the other but not both”)when preceded by terms of exclusivity, such as “either,” “one of,” “onlyone of,” or “exactly one of” “Consisting essentially of,” when used inthe claims, shall have its ordinary meaning.

As used herein in the specification and in the claims, the phrase “atleast one,” in reference to a list of one or more elements, should beunderstood to mean at least one element selected from any one or more ofthe elements in the list of elements, but not necessarily including atleast one of each and every element specifically listed within the listof elements and not excluding any combinations of elements in the listof elements. This definition also allows that elements may optionally bepresent other than the elements specifically identified within the listof elements to which the phrase “at least one” refers, whether relatedor unrelated to those elements specifically identified. Thus, as anon-limiting example, “at least one of A and B” (or, equivalently, “atleast one of A or B,” or, equivalently “at least one of A and/or B”) mayrefer, in one embodiment, to at least one, optionally including morethan one, A, with no B present (and optionally including elements otherthan B); in another embodiment, to at least one, optionally includingmore than one, B, with no A present (and optionally including elementsother than A); in yet another embodiment, to at least one, optionallyincluding more than one, A, and at least one, optionally including morethan one, B (and optionally including other elements); etc.

The term “based on” is not exclusive and allows for being based onadditional factors not described, unless the context clearly dictatesotherwise.

As used herein, “wt %” refers to weight percent.

The terms “roofing shingle” and “shingle” are used interchangeably.

In the claims, as well as in the specification above, all transitionalphrases such as “comprising,” “including,” “carrying,” “having,”“containing,” “involving,” “holding,” “composed of,” and the like are tobe understood to be open-ended, i.e., to mean including but not limitedto. Only the transitional phrases “consisting of” and “consistingessentially of” shall be closed or semi-closed transitional phrases,respectively.

The claims should not be read as limited to the described order orelements unless stated to that effect. It should be understood thatvarious changes in form and detail may be made by one of ordinary skillin the art without departing from the spirit and scope of the appendedclaims. All embodiments that come within the spirit and scope of thefollowing claims and equivalents thereto are claimed.

1. A method comprising: obtaining (a) a plurality of fragments of atleast one of a rock, a mineral, or a combination thereof and (b) abinder, wherein the plurality of fragments of the at least one of arock, a mineral, or a combination thereof comprises fragments having aparticle size passing US Mesh 40 but retained by US Mesh 270; and mixing(a) the plurality of fragments of the at least one of a rock, a mineral,or a combination thereof and (b) the binder to produce an unsinteredagglomerated particle that is formed by agglomerating together theplurality of fragments and the binder, the unsintered agglomeratedparticle being configured to be applied to a sheet to form a roofingproduct, wherein the at least one of a rock, a mineral, or a combinationthereof comprises at least one of basalt, metabasalt, andesite,rhyolite, or a combination thereof, wherein the unsintered agglomeratedparticle is substantially spherical, and wherein the binder is presentin the unsintered agglomerated particle in an amount of 2 wt % to 8 wt%.
 2. The method of claim 1, wherein the roofing product is a shingle orroll roofing. 3-5. (canceled)
 6. The method of claim 1, wherein thebinder is at least one of sodium silicate, gypsum, or a combinationthereof.
 7. The method of claim 1, wherein the agglomerated particle hasa coating comprising silicate and clay.
 8. The method of claim 1,wherein the mixing uses a pin mixer.
 9. The method of claim 1, furthercomprising pelletizing the agglomerated particle.
 10. The method ofclaim 1, further comprising drying the agglomerated particle.
 11. Amethod comprising: obtaining (a) a plurality of fragments of at leastone of a rock, a mineral, or combination thereof and (b) a binder,wherein the plurality of fragments of the at least one of a rock, amineral, or a combination thereof comprises fragments having a particlesize passing US Mesh 40 but retained by US Mesh 270; and mixing, using apin mixer, the plurality of fragments of the at least one of a rock, amineral, or a combination thereof and the binder to produce anagglomerated particle that is formed by agglomerating together theplurality of fragments and the binder, the agglomerated particle beingconfigured to be applied in unsintered form to a sheet to form a roofingproduct, wherein the at least one of a rock, a mineral, or a combinationthereof comprises at least one of basalt, metabasalt, andesite,rhyolite, or a combination thereof, wherein the binder is present in theagglomerated particle in an amount of 2 wt % to 8 wt %, and wherein theagglomerated particle is substantially spherical, wherein a plurality ofthe agglomerated particles are obtained by the method, and wherein, whenwt % is assessed with respect to a total weight of the agglomeratedparticles, (A) the agglomerated particles have a particle sizedistribution comprising (1) at least about 10 wt % retained by US Mesh50 after passing US Mesh 40, (2) at least about 5 wt % retained by USMesh 60 after passing US Mesh 50, and (3) at least about 5 wt % retainedby US Mesh 100 after passing US Mesh 70; or (B) the agglomeratedparticles have a particle size distribution comprising (1) at leastabout 40 wt % retained by US Mesh 16 after passing US Mesh 12, (2) atleast about 30 wt % retained by US Mesh 20 after passing US Mesh 16, and(3) at least about 20 wt % retained by US Mesh 30 after passing US Mesh20; or (C) the agglomerated particles have a particle size distributioncomprising (1) at least about 1 wt % retained by US Mesh 20 afterpassing US Mesh 16, (2) at least about 40 wt % retained by US Mesh 30after passing US Mesh 20, and (3) at least about 2 wt % retained by USMesh 40 after passing US Mesh
 30. 12. The method of claim 11, whereinthe agglomerated particles have a particle size distribution comprising(1) at least about 20 wt % retained by US Mesh 50 after passing US Mesh40, (2) at least about 10 wt % retained by US Mesh 60 after passing USMesh 50, and (3) at least about 10 wt % retained by US Mesh 100 afterpassing US Mesh
 70. 13. The method of claim 11, wherein the agglomeratedparticles have a particle size distribution comprising (1) at leastabout 30 wt % retained by US Mesh 50 after passing US Mesh 40, (2) atleast about 20 wt % retained by US Mesh 60 after passing US Mesh 50, and(3) at least about 20 wt % retained by US Mesh 100 after passing US Mesh70.
 14. The method of claim 11, wherein the agglomerated particles havea particle size distribution comprising (1) at least about 40 wt %retained by US Mesh 16 after passing US Mesh 12, (2) at least about 30wt % retained by US Mesh 20 after passing US Mesh 16, and (3) at leastabout 20 wt % retained by US Mesh 30 after passing US Mesh
 20. 15. Themethod of claim 11, wherein the agglomerated particles have a particlesize distribution comprising (1) at least about 2 wt % retained by USMesh 20 after passing US Mesh 16, (2) at least about 50 wt % retained byUS Mesh 30 after passing US Mesh 20, and (3) at least about 10 wt %retained by US Mesh 40 after passing US Mesh
 30. 16. The method of claim11, wherein the agglomerated particles have a particle size distributioncomprising (1) at least about 5 wt % retained by US Mesh 20 afterpassing US Mesh 16, (2) at least about 60 wt % retained by US Mesh 30after passing US Mesh 20, and (3) at least about 20 wt % retained by USMesh 40 after passing US Mesh
 30. 17-18. (canceled)
 19. The method ofclaim 11, wherein the binder is at least one of sodium silicate, gypsum,or a combination thereof.
 20. The method of claim 11, wherein theagglomerated particle has a coating comprising silicate and clay. 21.The method of claim 11, further comprising drying the agglomeratedparticles.
 22. The method of claim 11, wherein the at least one of arock, a mineral, or a combination thereof comprises metabasalt.
 23. Themethod of claim 1, wherein the at least one of a rock, a mineral, or acombination thereof comprises basalt.
 24. The method of claim 1, whereinthe at least one of a rock, a mineral, or a combination thereofcomprises metabasalt.
 25. The method of claim 1, wherein the at leastone of a rock, a mineral, or a combination thereof comprises andesite.26. The method of claim 1, wherein the at least one of a rock, amineral, or a combination thereof comprises rhyolite.
 27. The method ofclaim 1, wherein the binder comprises gypsum.
 28. (canceled)
 29. Themethod of claim 1, wherein the agglomerated particle has a coatingcomprising silicate and clay, and wherein the at least one of a rock, amineral, or a combination thereof is basalt.
 30. (canceled)